SVM103-A
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SVM103-A
POWER-ARC 4000
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you
act and be careful.
TM
For use with machine code number 10083
December 1995
World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
View Safety Info View Safety Info View Safety Info View Safety Info
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SERVICE MANUAL
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR
DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
____________________________________________________
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi-
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle con-
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trol rods while the engine is running.
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
POWER-ARC 4000
SAFETY
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable
and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
vapors
to
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5.e. Also see item 1.b.
Mar ‘95
POWER-ARC 4000
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
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POWER-ARC 4000
Mar ‘95
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous ten-
sion quand la machine à souder est en marche. Eviter
toujours tout contact entre les parties sous tension et
la peau nue ou les vétements mouillés. Porter des
gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand
on soude dans des endroits humides, ou sur un
plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour
lesquelles une grande partie du corps peut être en
contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le
câble de soudage et la machine à souder en bon et
sûr état defonctionnement.
d. Ne jamais plonger le porte-électrode dans l’eau pour
le refroidir.
e. Ne jamais toucher simultanément les parties sous
tension des porte-électrodes connectés à deux
machines à souder parce que la tension entre les
deux pinces peut être le total de la tension à vide des
deux machines.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc.
Ne jamais enroule le câble-électrode autour de n’importe
quelle partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant appro-
prié ainsi qu’un verre blanc afin de se protéger les
yeux du rayonnement de l’arc et des projections
quand on soude ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnementde l’arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laiter en fusion sont émises de l’arc de
soudage. Se protéger avec es vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise
épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans
les zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin
de prévenir ttout risque d’incendie dû étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé
de la masse. Un court-circuit accidental peut provoquer
un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de la faire. Si on
place la masse sur la charpente de la construction ou
d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par
les chaines de levage, câbles de grue, ou atres circuits.
Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se
rompent.
9. Assurer une ventilation suffisante dans la zone de
soudage. Ceci est particuliérement important pour le
soudage de tôles galvanisées plombées, ou cadmiées ou
tout autre métal qui produit des fumées toxiques.
10. Ne pas souder en présence de vapeurs de chlore
provenant d’opéerations de dégraissage, nettoyage ou
pistolage. La chaleur ou les rayons de l’arc peuvent réagir
avec les vapeurs du solvant pour produire du phosgéne
(gas fortement roxique) ou autres produits irritants.
PRÉCAUTIONS DE SÛRETÉ POUR LES
MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le
dispositif de montage ou la piece à souder doit être
branché à une bonne mise à la terre.
2. Autant que possible, l’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispostifis de sûreté à leur
place.
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POWER-ARC 4000
v
RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications.............................................................................................................A-1
Safety Precautions ......................................................................................................................A-2
Location and Ventilation.............................................................................................................A-2
Pre-operation Engine Service.....................................................................................................A-3
Electrical Output Connections....................................................................................................A-4
Operation...............................................................................................................................Section B
Safety Instructions......................................................................................................................B-1
General Description....................................................................................................................B-1
Recommended Applications ......................................................................................................B-2
Page
Operational Features and Controls ............................................................................................B-2
Design Features and Advantages ..............................................................................................B-2
Welding Capability ......................................................................................................................B-2
Limitations .................................................................................................................................B-2
Controls and Settings.................................................................................................................B-3
Engine Operation........................................................................................................................B-5
Accessories...........................................................................................................................Section C
Maintenance .........................................................................................................................Section D
Safety Precautions............................................................................................................................D-1
Routine and Periodic Maintenance ...................................................................................................D-1
Major Component Locations ............................................................................................................D-5
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual.................................................................................................................................P-233
POWER-ARC 4000
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications.............................................................................................................A-1
Safety Precautions ......................................................................................................................A-2
Location and Ventilation.............................................................................................................A-2
Storing .................................................................................................................................A-2
Stacking................................................................................................................................A-3
Tilting .................................................................................................................................A-3
Lifting .................................................................................................................................A-3
Pre-operation Engine Service.....................................................................................................A-3
Oil ........................................................................................................................................A-3
Fuel.......................................................................................................................................A-3
Section A
Muffler Deflector ...................................................................................................................A-3
Spark Arrester ......................................................................................................................A-3
Electrical Output Connections....................................................................................................A-4
Welding Cable Connections.................................................................................................A-4
Cable Size and Length............................................................................................A-4
Cable Installation.....................................................................................................A-5
Machine Grounding..............................................................................................................A-5
Plugs and Hand-Held Equipment .......................................................................................A-5
Auxiliary Power Receptacles ................................................................................................A-5
Premises Wiring....................................................................................................................A-6
Circuit Breakers ....................................................................................................................A-6
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POWER-ARC 4000
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER-ARC 4000
INPUT - GASOLINE ENGINE
Manufacturer Description Speed Displacement Ignition Capacities
Briggs & 1 cyl., 3700 RPM 19.4 cu. in. Manual, Fuel: 1.0 gal. (3.8 l)
Stratton Cool- 4 cycle ± 50 RPM (319 cc) Recoil
®
Bore
air-cooled at no load start; Manual Oil: 1.4 qt. (1.3 l)
gasoline choke
8 HP @
3750 RPM
RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
30% Duty Cycle 125 18 VAC
60% Duty Cycle 100 25 VAC
OUTPUT - WELDER AND GENERATOR
Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power
70 - 125 Amps 62 VAC Max. 4000 Continuous Watts
4400 Surge Watts
PHYSICAL DIMENSIONS
Height Width Depth Weight
20.9 in. 20 in. 30 in. 160 lb.
530 mm 508 mm 762 mm 72.5 kg
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POWER-ARC 4000
INSTALLATION
A-2
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
• Insulate yourself from the
work and ground.
•Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust to the
outside.
• Do not stack anything on or near the engine.
LOCATION AND VENTILATION
Whenever you use the POWER-ARC 4000, be sure
that clean cooling air can flow through the machine’s
gasoline engine and the generator. Avoid dusty, dirty
areas. Also, keep the machine away from heat
sources. Do not place the back end of the generator
anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
exhaust is ventilated to an open, outside area.
The POWER-ARC 4000 may be used outdoors. Do
not set the machine in puddles or otherwise submerge
it in water. Such practices pose safety hazards and
cause improper operation and corrosion of parts.
Always operate the POWER-ARC 4000 with the case
roof on and all machine components completely
assembled. This will protect you from the dangers of
moving parts, hot metal surfaces, and live electrical
devices.
STORING
1. Store the machine in a cool, dry place when it’s
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from construction activities, moving vehicles, and other
hazards.
2. If you will be storing the machine for over 30 days,
you should drain the fuel to protect fuel system
and carburetor parts from gum deposits. Empty
all fuel from the tank and run the engine until it
stops from lack of fuel.
MOVING PARTS can injure.
• Keep away from moving parts.
Only qualified personnel should install, use, or service
this equipment.
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• Do not operate this equipment with any of its doors
open or guards off.
• Stop the engine before servicing it.
3. You can store the machine for up to 24 months if
you use Briggs & Stratton Gasoline Additive, Part
No. 5041 (available from any Authorized Briggs &
Stratton Service Center), in the fuel system. Mix
the additive with the fuel in the tank and run the
engine for a short time to circulate the additive
through the carburetor.
4. While the engine is still warm, drain the oil and
refill with fresh 10W30 oil.
5. Remove the spark plug and pour approximately
1/2 ounce (15 ml) of engine oil into the cylinder.
Replace the spark plug and crank the engine
slowly to distribute the oil.
6. Clean any dirt and debris from the cylinder and
cylinder head fins and housing, rotating screen,
and muffler areas.
7. Store in a clean, dry area.
POWER-ARC 4000
A-3
INSTALLATION
STACKING
POWER-ARC 4000 machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
The gasoline engine is designed to run in a level position for best performance. It can operate at an angle,
but this should never be more than 15 degrees in any
direction. If you do operate it at a slight angle, be sure
to check the oil regularly and keep the oil level full.
Also, fuel capacity will be a little less at an angle.
LIFTING
The POWER-ARC 4000 should be lifted by two people. (It weighs 160 lbs/72.5 kg.) Its welded tube roll
cage is designed to make lifting easy.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the gasoline engine in the OPERATION and MAINTENANCE
sections of this manual before you operate the
POWER-ARC 4000.
WARNING
• Keep hands away from the engine muffler or HOT
engine parts.
• Stop the engine when fueling.
FUEL
Fill the fuel tank with clean, fresh, regular
grade lead-free gasoline. DO NOT MIX
OIL WITH THE GASOLINE.
The POWER-ARC 4000 has a plastic, 1.00
gallon (3.8) fuel tank mounted on the engine. See the
OPERATION and MAINTENANCE sections of this
manual for more details about fuel.
MUFFLER DEFLECTOR
The POWER-ARC 4000 is shipped with an exhaust
deflector. You can mount it yourself on the gasoline
engine.
To install the deflector, do the following:
• Align the holes on the deflector plate with the holes
on the muffler.
• Position the deflector so that the opening points
either right, left, or downward, away from the operator.
CAUTION
Never position the deflector upward. Moisture or
debris can enter the engine and damage it. As a general safety practice, position the deflector to direct
exhaust gases away from the operator’s face and
eyes.
• Fasten the deflector onto the muffler with the screws
provided.
NOTE: The deflector reduces generator output power
up to 100 watts.
• Do not smoke when fueling.
• Remove the fuel cap slowly to release pressure.
• Do not overfill the fuel tank.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
• Keep sparks and flame away from the fuel tank.
OIL
The POWER-ARC 4000 is shipped with
the engine filled with SAE 10W-30 oil.
CHECK THE OIL LEVEL BEFORE YOU START THE
ENGINE. This is an added precaution. When full, the
oil level should be at the top of the fill plug hole. If it
is not full, add enough oil to fill it. Be sure the fill plug
is tight.
For more oil fill and service information, see the MAINTENANCE section of this manual.
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POWER-ARC 4000
SPARK ARRESTER
Gasoline engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.
Standard mufflers and deflectors (like the ones included with the POWER-ARC 4000) do not act as spark
arresters. When local laws require it, a spark arrester
must be installed on the machine and properly maintained. An optional spark arrester kit is available for
your POWER-ARC 4000. See the ACCESSORIES
section of this manual for more information.
CAUTION
An incorrect spark arrester may lead to damage to the
engine or reduce performance. A suitable spark
arrester for the Briggs & Stratton 8 HP Cool Bore
engine is available as a Lincoln field-installed option.
®
INSTALLATION
FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS
1
A-4
70
AMPS
125
AMPS
GENERATOR
WARNING
ELECTRODE SELECTION GUIDE
2
1. CURRENT CONTROL DIAL
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD
80
AMPS
90
AMPS
100
AMPS
POWER ARC 4000
6
5
3
4
4. CIRCUIT BREAKERS (2) - 20 AMP
5. RECEPTACLE - 240 VOLT, 20 AMP
6. DUPLEX RECEPTACLE - 120 VOLT, 20 AMP
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the current control
dial, weld output terminals, ground stud, circuit breakers, 240 and 120 volt receptacles.
WELDING CABLE CONNECTIONS
Cable Size and Length
Be sure to use welding cables that are large enough.
The correct size and length becomes especially
important when you are welding at a distance from the
welder.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
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TABLE A.1
RECOMMENDED WELDING CABLE
SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE
AND WORK CABLES
Cable Size for
125 amp/
Cable Length 30% Duty Cycle
0-50 feet (0-15 meters) 6 AWG
50-100 feet (15-39 meters) 4 AWG
100-150 feet (30-46 meters) 3 AWG
150-200 feet (46061 meters) 2 AWG
200-250 feet (61-76 meters) 1 AWG
POWER-ARC 4000
A-5
INSTALLATION
Cable Installation
Install the welding cables to your POWER-ARC 4000
as follows. See Figure A.1 for the location of parts.
1. The gasoline engine must be OFF to install weld-
ing cables.
2. Remove the 1/2 - 13 flanged nuts from the output
terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. You can connect either
cable to either terminal, since the POWER-ARC
4000 provides AC weld current.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding
(the “work”) is securely connected to the work
clamp and cable.
6. Check and tighten the connections periodically.
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the ACCES-
SORIES section of this manual for more information.
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
When the POWER-ARC 4000 is mounted
on a truck or a trailer, the machine generator ground stud MUST be securely
connected to the metal frame of the vehicle. See Figure A.1. The ground stud is
marked with the symbol.
PLUGS AND HAND-HELD EQUIPMENT
For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an
Underwriter’s Laboratories (UL) approved double
insulation system with a two-blade plug. Lincoln
offers an accessory plug kit that has the right type of
plugs. See the ACCESSORIES section of this manual for details.
If you need ground fault protection for hand-held
equipment, in-line ground fault current interrupter
(GFCI) cord sets that meet UL and OSHA requirements are available from:
Ericson Manufacturing Company
Willoughby, Ohio 44094
(216) 951-8000 (Ohio)
1-800-972-5109 (outside Ohio)
AUXILIARY POWER RECEPTACLES
MACHINE GROUNDING
Because the POWER-ARC 4000 creates its own
power from its gasoline-engine driven generator, you
do not need to connect the machine frame to an earth
ground. However, for best protection against electri-
ground.
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cal shock, connect a heavy gauge wire
from the ground stud located on the
bottom center of the output panel (see
Figure A.1) to a suitable earth ground
such as a metal pipe driven into the
The control panel of the POWER-ARC 4000 features
two auxiliary power receptacles:
• A 20 amp, 120 volt duplex (double outlet) receptacle
• A 20 amp 240 volt simplex (single outlet) receptacle.
See Figure A.1.
Through these receptacles the machine can supply up
to 4,000 rated continuous watts and 4,400 surge watts
of single-phase AC power. The machine output voltages meet UL standards and fall within ± 10% of the
rated voltage. The output frequency falls within ± 3%
of rated frequency (60 Hz).
POWER-ARC 4000
INSTALLATION
A-6
PREMISES WIRING
The POWER-ARC 4000 three-wire, grounded neutral
generator allows it to be connected to premises
wiring. However, the wiring procedure needed to
meet the National Electric Code (NEC) regulations as
well as city ordinances can be confusing. Matters get
worse depending on whether you want the machine to
be “hardwired” to the premises or only connected
temporarily.
WARNING
Only a licensed, certified, trained electrician should
install the machine to a premises or residential electrical system. Be certain that:
• The premises is isolated and no feedbacking into
the utility system can occur. Certain state and local
laws require the premises to be isolated before the
generator is linked to the premises. Check your
state and local requirements.
• A double pole, double throw transfer switch in conjunction with the properly rated double throw circuit
breaker is connected between the generator power
and the utility meter.
CIRCUIT BREAKERS
The POWER-ARC 4000 has its own
20 amp circuit breakers for overload
protection. When the machine is
operated in high temperature environments, the
breakers may tend to trip at lower loads than normally.
CAUTION
Never bypass the circuit breakers. Without overload
protection, the power-arc 4000 could overheat and/or
cause damage to the equipment being used.
The POWER-ARC 4000 (unlike other Lincoln Electric
equipment) does not have a combined 120/240 volt
twist-lock receptacle and cannot be connected to a
premises as described in other Lincoln literature.
Remember that the POWER-ARC 4000 is intended
only for backup, intermittent use. The gasoline engine
has a rated life of 500 hours. It cannot withstand longterm use without proper maintenance. See the MAIN-
TENANCE section of this manual for more information.
Certain electrical devices cannot be powered by the
POWER-ARC 4000. Refer to Table A.2 for these
devices.
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POWER-ARC 4000
A-7
INSTALLATION
CAUTION
Certain Electrical devices cannot be powered by the POWER-ARC 4000. See Table A.2.
TABLE A.2
ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000.
Type Common Electrical Devices Possible Concerns
Resistive Heaters, toasters, incandescent NONE
light bulbs, electric range, hot
pan, skillet, coffee maker.
Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage
appliances with electrical control. regulation can cause the capac-
itative elements to fail. Surge
protection, transient protection,
and additional loading is recommended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.
Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting. (See
refrigerators, weed and hedge Table B.3, GENERATOR POWER
trimmers APPLICATIONS, in the OPERA-
TION section of this manual for
required starting wattages.)
Some synchronous motors may
be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.
Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-
complicated electrical equipment. er along with transient and
surge protection is required,
and liabilities still exist. DO
NOT USE THESE DEVICES
WITH A POWER-ARC 4000.
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the POWER-ARC 4000.
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POWER-ARC 4000
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions......................................................................................................................B-1
General Description....................................................................................................................B-1
Recommended Applications ......................................................................................................B-2
Generator
Welder
Operational Features and Controls ............................................................................................B-2
Design Features and Advantages ..............................................................................................B-2
Welding Capability ......................................................................................................................B-2
Limitations .................................................................................................................................B-2
Controls and Settings ................................................................................................................B-3
Generator/Welder Controls..................................................................................................B-3
Gasoline Engine Controls.....................................................................................................B-4
Engine Operation........................................................................................................................B-5
Before Starting the Engine ..................................................................................................B-5
Starting the Engine ..............................................................................................................B-5
Stopping the Engine ............................................................................................................B-6
Running the Engine .............................................................................................................B-6
Break-in Period ....................................................................................................................B-6
Section B
Generator Operation...................................................................................................................B-7
Welding Operation......................................................................................................................B-9
Welding Guidelines...................................................................................................................B-10
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POWER-ARC 4000
B-1
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your POWER-ARC 4000.
SAFETY INSTRUCTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
WARNING
ARC RAYS can burn.
• Wear eye, ear, and body protection.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
MOVING PARTS can injure.
• Do not operate this equipment with
any of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
Only qualified personnel should install, use, or service this equipment.
GENERAL DESCRIPTION
The POWER-ARC 4000 is a low-cost generator/
welder designed for home use and other non-commercial applications. As a generator it can supply up
to 4,000 continuous watts (or 4,400 surge watts) of
120/240 volt, single-phase AC power. As a welder it
provides 125 amps of AC current for welding with AC
stick electrodes. A single dial provides continuous
adjustment of welding output. The machine is lightweight, portable, and can be lifted easily by two people.
A Briggs & Stratton 8 HP standard Cool-Bore®aircooled, gasoline engine powers the generator/welder.
The engine has an approximate operating life of 500
hours.
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POWER-ARC 4000
OPERATION
B-2
The POWER-ARC 4000 warranty covers the machine
for one year from the date of purchase. For nonengine warranty claims, contact your nearest Lincoln
Authorized Field Service Facility. For engine warranty
claims, contact your nearest Briggs & Stratton service
center.
NOTE: The POWER-ARC 4000 is not meant for rental
or other commercial use.
RECOMMENDED APPLICATIONS
GENERATOR
The POWER-ARC 4000 gives smooth AC generator
output for medium use, non-commercial demands.
For more details on operating the generator, see GENERATOR OPERATION in the OPERATION section of
this manual.
WELDER
The POWER-ARC 4000 provides excellent constant
current AC welding output for stick (SMAW) welding.
For more details on using the machine as a welder,
see WELDING OPERATION in the OPERATION section of this manual.
OPERATIONAL FEATURES AND
CONTROLS
The POWER-ARC 4000 was designed for simplicity.
Therefore, it has very few operating controls. A single
dial on the control panel lets you select either generator or welding use. For welding, the same dial selects
continuous current output over the machine’s 70 to
125 amp range.
• Separate ground stud for safe connection of case to
earth ground. Single 20 amp, 240 volt generator
receptacle.
• Duplex 20 amp, 120 volt generator receptacle.
• Integrated generator output overload protection
through two 20 amp circuit breakers.
• Welded-tube, full roll cage frame protects engine
and generator/welder.
• Lightweight, portable design.
• Rubber mounting isolates engine and generator
from frame to prevent machine “walking” during
use.
• Lo-Tone®engine muffler for quieter operation. (A
Super Lo-Tone®muffler is available from Briggs &
Stratton.) Easy-starting Electronic Magnetron®ignition.
• Optional Oil Gard®low oil level engine shutdown kit
available from Briggs & Stratton.
WELDING CAPABILITY
The POWER-ARC 4000 is rated 125 amps, 18 volts at
30% duty cycle on a ten-minute basis. This means
that you can load the welder to 125 amps for three
minutes out of every ten-minute period. The machine
is capable of higher duty cycles at lower output currents. For example, you can load the welder to 100
amps for six minutes out of ten for a 60% duty cycle.
The current is continuously variable from 70 to 125
amps AC. The POWER-ARC 4000 can, therefore,
weld with all 3/32 and most 1/8 inch diameter Lincoln
AC electrodes.
The 8 HP Briggs & Stratton gasoline engine controls
include a recoil starter, choke, throttle control, and
piercing stop switch. See ENGINE OPERATION in the
OPERATION section of this manual for details about
starting, running, stopping, and breaking in the gasoline engine.
DESIGN FEATURES AND
ADVANTAGES
• Stick welding (SMAW) process capability with output range from 70 - 125 amps.
• Single-dial current output selection.
• Work and Electrode welding cable mounting terminals.
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LIMITATIONS
• The POWER-ARC 4000 is not recommended for
any processes besides those that are normally performed using stick welding (SMAW) procedures.
• The POWER-ARC 4000 is not recommended for
pipe thawing.
• During welding, generator power is limited to 100
watts, and output voltages can drop from 120 to 80
volts and 240 to 160 volts. Therefore, DO NOT
OPERATE ANY SENSITIVE ELECTRICAL EQUIPMENT WHILE YOU ARE WELDING.
POWER-ARC 4000
B-3
OPERATION
CONTROLS AND SETTINGS
All generator/welder controls are located on the
Output Control Panel. Gasoline engine controls are
mounted on the engine. See Figures B.1 and B.2 and
the explanations that follow.
FIGURE B.1 – OUTPUT PANEL CONTROLS
1
80
70
AMPS
AMPS
125
AMPS
GENERATOR
WARNING
2
ELECTRODE SELECTION GUIDE
3
1. CURRENT CONTROL DIAL
2. ELECTRODE SELECTION GUIDE
3. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH 1/2 - 13 FLANGE NUT
4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13 FLANGE NUT
5. GROUND STUD
6. 20 AMP CIRCUIT BREAKERS (2)
7. 20 AMP, 240 VOLT RECEPTACLE
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE
90
AMPS
100
AMPS
4
POWER ARC 4000
5
8
7
6
GENERATOR/WELDER CONTROLS
See Figure B.1 for the location of the following features:
1. CURRENT CONTROL DIAL: Adjusts continuous
current output. The amperages on the dial correspond to the average amperages needed for specific Lincoln welder rods.
2. ELECTRODE SELECTION GUIDE: Provides recommended electrode type, size, and welder output setting based on the thickness of the work.
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POWER-ARC 4000
3. WELD OUTPUT TERMINAL (TO ELECTRODE
HOLDER) WITH 1/2 - 13 FLANGE NUT: Provides
the connection point for either the electrode holder or the work cable. (Because the POWER-ARC
4000 is an AC output machine, either output terminal can be used for either cable.)
4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2
- 13 FLANGE NUT: Provides the connection point
for either the electrode holder or the work cable.
(Because the POWER-ARC 4000 is an AC output
machine, either output terminal can be used for
either cable.)
OPERATION
B-4
5. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure.
6. 20 AMP CIRCUIT BREAKERS (2): Provide separate overload current protection for the 120 volt
and 240 volt receptacles.
FIGURE B.2 – GASOLINE ENGINE CONTROLS
2
AIR
IN
ENGINE
R
LINCOLN
1
OUT
ELECTRIC
AIRAIR
OUT
EXHAUST
7. 20 AMP, 240 VOLT RECEPTACLE: Connection
point for supplying 240 volt power to operate one
electrical device.
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE:
Connection point for supplying 120 volt power to
operate one or two electrical devices.
5
6
80
70
AMPS
AMPS
MIN.
MAX.
100
AMPS
ELECTRODE SELECTION GUIDE
90
AMPS
POWER ARC 4000
3
4
7
8
GASOLINE ENGINE CONTROLS
See Figure B.2 for the location of the following features:
1. FUEL SHUTOFF VALVE: Stops the flow of gasoline from the fuel tank to the carburetor. Should
be closed whenever you are finished using the
POWER-ARC 4000. Must be opened before you
start the engine.
2. FUEL TANK AND CAP: Holds 1.0 gallon (3.8
liters) of unleaded gasoline. Contains a 50
micron fuel filter molded at the outlet port.
NOTE: If you use any other alternate fuel tank or
supply, be sure to use a recommended
in-line fuel filter.
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1. FUEL SHUTOFF VALVE
2. FUEL TANK AND CAP
3. MUFFLER
4. PIERCING STOP SWITCH
5. AIR CLEANER
6. THROTTLE
9
11
12
7. AIR MIXTURE ADJUSTMENT SCREW
8. RECOIL STARTER
9. CHOKE
10. FUEL MIXTURE ADJUSTMENT SCREW
11. OIL DRAIN PLUG
12. OIL FILL PLUG
3. MUFFLER: Reduces engine noise output. Does
not serve as a spark arrester. See SPARK
ARRESTER in the INSTALLATION section of
this manual.
4. PIERCING STOP SWITCH: Stops the engine by
grounding the spark plug.
5. AIR CLEANER: Filters intake air to the carburetor. See ENGINE MAINTENANCE in the MAIN-
TENANCE section of this manual for details
about the specific type of air cleaner to use.
6. THROTTLE: Adjusts the running speed of the
engine. The engine runs at high idle
when not under load. Rotating the
spring-loaded throttle clockwise can
temporarily reduce engine speed to
low idle speed. Releasing the throttle returns the
speed to high idle.
10
POWER-ARC 4000
B-5
OPERATION
7. AIR MIXTURE ADJUSTMENT SCREW: Adjusts the
amount of air mixed with fuel to obtain the
smoothest operation under load or at idle. The
POWER-ARC 4000 is shipped with the proper
adjustment already set. DO NOT ADJUST THE
AIR MIXTURE SCREW WITHOUT FOLLOWING
THE PROCEDURES OUTLINED BY BRIGGS &
STRATTON.
8. RECOIL STARTER: Manual, rope-type starter.
The handle position allows easy starting from
either ground level or pickup-truck level.
9. CHOKE: Provides a richer air/fuel
mixture for cold engine starting conditions. See the topic ENGINE
OPERATION, below, for details on setting the
choke.
10. FUEL MIXTURE ADJUSTMENT SCREW: Adjusts
the amount of fuel mixed with air to obtain the
smoothest operation under load or at idle. The
POWER-ARC 4000 is shipped with the proper
adjustment already set. DO NOT ADJUST THE
FUEL MIXTURE SCREW WITHOUT FOLLOWING THE PROCEDURES OUTLINED BY BRIGGS & STRATTON.
11. OIL DRAIN PLUG: Permits convenient draining of
engine oil during maintenance. Both sides of the
engine are equipped with an oil drain plug.
12. OIL FILL PLUG: Permits convenient filling of
engine oil during maintenance. Both sides of the
engine are equipped with an oil fill plug.
ENGINE OPERATION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS.
The maximum allowable high idle speed for the
POWER-ARC 4000 is 3750 RPM, no load. Do NOT
adjust the governor screw on the engine. Severe personal injury and damage to the machine can result if it
is operated at speeds above the maximum rated
speed.
BEFORE STARTING THE ENGINE
CHECK AND FILL THE ENGINE OIL LEVEL:
1. Place the machine on a level
surface.
2. Open the oil fill plug.
3. Fill (if necessary) until oil flows out the top of the fill
plug hole.
4. Replace the fill plug and tighten securely.
CHECK AND FILL THE ENGINE FUEL TANK:
1. Remove the fuel tank cap.
2. Fill the tank to allow approximately 1/4
inch (5 mm) of tank space for fuel
expansion. DO NOT FILL THE TANK
TO THE POINT OF OVERFLOW.
3. Replace the fuel tank cap and tighten securely.
NOTE: The engine will operate satisfactorily on any
gasoline meant for automotive use. A minimum of 87 octane is recommended. DO NOT
MIX OIL WITH THE GASOLINE.
Use clean, fresh, lead-free gasoline. Leaded gasoline
may be used if lead-free is not available. However,
lead-free gasoline leaves fewer combustion deposits
and gives longer valve life. For engine protection from
fuel deposits, use Briggs & Stratton Gasoline Additive,
part number 5041. Purchase gasoline in quantities
that will be used within 30 days, to assure freshness.
NOTE: We DO NOT recommend using gasoline that
contains alcohol, such as gasohol. However,
if gasoline with alcohol is used, it MUST NOT
contain more than 10% Ethanol and MUST be
removed from the engine during storage. DO
NOT use gasoline containing Methanol.
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power
receptacles before starting the gasoline
engine.
FOR A “COLD” ENGINE:
1. Open the fuel shutoff valve on the bottom of the
fuel tank.
Read and understand all safety instructions included
in the Briggs & Stratton Operating and Maintenance
Instructions manual that is shipped with the POWERARC 4000.
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POWER-ARC 4000
2. Place the choke lever in the lowest, downward
position.
3. Pull slightly on the recoil starter handle
until resistance is felt.
OPERATION
B-6
4. Pull the cord rapidly.
5. If the engine does not start, open the choke slightly (move lever upward) and pull the starter cord
rapidly again.
When the engine starts, gradually open the choke to
the highest, upward position.
FOR A “HOT” ENGINE:
1. Open the fuel shutoff valve on the bottom of the
fuel tank.
2. Place the choke lever in the highest,
upward position. Closing the choke
of a hot engine will flood the carburetor and prevent starting.
3. Pull slightly on the recoil starter handle until resistance is felt.
4. Pull the cord rapidly.
FOR BEST ENGINE STARTING:
• Do not adjust air or fuel mixtures without following
the procedures in the Briggs & Stratton Operating
and Maintenance Instructions manual.
• Always use fresh gasoline and be sure the filter is
clean and properly maintained.
• If you use an alternate fuel tank or supply, be sure
to install an in-line fuel filter.
• Do not pull the recoil starter with the
choke in the downward position more
than one time. Repeated pulls on a
choked engine will flood the carburetor.
• If you don’t feel resistance when you pull the recoil
cord, gently hit the starter housing and/or pull the
cord out to its fully extended position and wiggle it
rapidly. Repeat this if necessary until the clutch
engages the shaft and you feel resistance when you
pull the cord.
• If the engine will not start, see the TROU-
BLESHOOTING section of this manual.
STOPPING THE ENGINE
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes.
FOR BEST ENGINE STOPPING:
• Do not remove the rubber spark plug boot.
• Be sure the piercing point on the piercing stop
switch lever firmly contacts the spark plug.
• Do not apply excessive force to or bend the piercing stop switch lever.
WARNING
Close the fuel valve when the machine is transported
to prevent fuel leakage from the carburetor. Drain the
tank before transporting the machine in a vehicle.
For long periods of storage, turn off the fuel shutoff
valve (lowest, downward position) and let the engine
run until there is no more fuel in the line. Use a fuel
additive such as Sta-Bil to minimize fuel gum
deposits.
RUNNING THE ENGINE
The engine is set at the factory to run at high idle
speed when not under load. You should not adjust
this setting yourself.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its
“break-in” period. For the gasoline engine on the
POWER-ARC 4000, break-in is about 12 running
hours.
Check the oil frequently during break-in. Change the
oil after the first 5 hours of operation. For more
details, see the MAINTENANCE section of this manual.
CAUTION
During break-in, subject the POWER-ARC 4000 to
only moderate loads. Avoid long periods running at
idle. Before stopping the engine, remove all loads and
allow the engine to cool several minutes.
2. Stop the engine by pressing downward on the
piercing stop switch lever.
3. Hold the lever down firmly until the engine completely stops. Otherwise, the engine may restart
or sputter as it stops.
4. Close the fuel shutoff valve at the bottom of the
fuel tank.
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POWER-ARC 4000
B-7
OPERATION
GENERATOR OPERATION
CAUTION
Be sure that any electrical equipment plugged into the
generator’s AC power receptacles can withstand a
±10% voltage and a ±3% frequency variation. Some
electronic devices cannot be powered by the POWERARC 4000. Refer to Table A.2, ELECTRICAL DEVICE
USE WITH THE POWER-ARC 4000, in the INSTALLATION section of this manual.
GENERAL INFORMATION
The POWER-ARC 4000 generator is rated at 4000
continuous watts (4400 surge watts). It provides both
120 volt and 240 volt power. You can draw up to 20
amps from either side of the 120 volt duplex receptacle, but no more than 37 amps from both sides at
once. Up to 18 amps can be drawn from the single
240 volt receptacle.
Electrical loads in watts are calculated by multiplying
the voltage rating of the load by the number of amps it
draws. (This information is given on the load device
nameplate.) For example, a device rated 115 volts, 2
amps will need 230 watts of power (115 x 2 = 230).
You can use Table B.3, GENERATOR POWER APPLICATIONS, to determine the wattage requirements of
the most common types of loads you can power with
the POWER-ARC 4000. Be sure to read the notes at
the bottom of the table.
TO USE THE GENERATOR AS AN AUXILIARY
POWER SUPPLY:
1. Start the gasoline engine. See ENGINE OPERATION in this section of the manual.
2. Set the current control dial on the output control
panel to “GENERATOR.” See Figure B.1.
3. Plug the load(s) into the appropriate 120 volt or
240 volt power receptacle.
NOTE: During welding, the maximum generator out-
put for auxiliary loads is 100 watts.
NOTE: You can supply multiple loads as long as the
total load does not exceed 4,000 watts. Be
sure to start the largest loads first.
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POWER-ARC 4000
OPERATION
TABLE B.3
GENERATOR POWER APPLICATIONS
Suggested Power Applications Running Watts *Start-up Watts
*Air Compressor - 3/4 HP 1,250 3,100 - 5,000
*Airless Sprayer - 1/3 HP 600 1,500 - 2,400
Chain Saw 1,200
Circular Saw 1,200
Coffee Maker 1,000
*Deep Freezer 500 750 - 2,000
*Electric Motor - 1 HP 1,000 2,500 - 4,000
Electric Range (1 element) 1,500
Electric Skillet 1,250
*Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln 100 or 125 Amp Wire Feeder/Welder 4,000
B-8
NOTES:
Wattages listed are approximate. Check your equipment for actual wattage.
Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment listed in
the table, multiply RUNNING WATTS by 2.
Multiple loads can be used as long as the total load does not exceed 4,000 watts. Be sure to start the
largest loads first. For example, a 1 HP motor needs approximately 1,000 watts while running but may
require 2,500 watts to start. Some inductive motors may require as much as 4 times running watts to
start.
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POWER-ARC 4000
B-9
OPERATION
WELDING OPERATION
GENERAL INFORMATION
WARNING
Do not touch electrically live parts or electrodes with your skin or wet clothing.
Do not breathe welding fumes or gases.
Use ventilation or exhaust to remove weld-
ing fumes from the breathing area.
Keep flammable material away.
Wear eye, ear, and body protection.
The POWER-ARC 4000 generator/welder can deliver
from 70 to 125 amps of continuous welding output
current . Output can be adjusted by setting the current control dial on the output control panel.
3. Attach the work clamp securely to the work you
are welding.
4. Insert the electrode into the electrode holder.
5. Set the current control dial to the desired output
current.
6. Start the gasoline engine. See ENGINE OPERA-
TION in this section of the manual.
7. Strike an arc and begin welding. For information
on welding techniques, see WELDING GUIDE-
LINES in this section of the manual.
AFTER YOU FINISH THE WELD:
1. Stop the gasoline engine. See ENGINE OPERATION in this section of the manual.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode from the
electrode holder.
5. If you are finished using the POWER-ARC 4000 for
welding, disconnect the welding cables from the
weld output terminals. Reattach the flange nuts
and leave them on the terminals.
You can get maximum welding output by setting the
dial to 125 AMPS. At high current settings like this,
some output may decrease as the machine is used. If
you are welding for a long time, you may need to turn
the dial slightly upward to maintain the same results.
The numbers on the dial correspond to the average
amps needed to weld using specific Lincoln welding
rods. Table B.4, WELDING APPLICATIONS, gives you
the recommended dial settings based on the thickness of the work and the size and type of rod you’re
using.
TO USE THE POWER-ARC 4000 FOR WELDING:
1. Remove the flange nuts from the weld output terminals and place the work and electrode welding
cables over the terminals. See Figure B.1.
Replace and tighten the flange nuts securely. Be
sure the connections are tight.
2. Select the appropriate electrode. See Table B.4,
WELDING APPLICATIONS, or the ELECTRODE
SELECTION GUIDE on the machine Output
Control Panel.
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POWER-ARC 4000
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